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An Insight Into

Single Section Digital Axle Counter (SSDAC-G36)

Approved by RDSO
To SPEC No. RDSO/SPN/177/2005 Ver 2.0 with Amendment 1

By

G.G.Tronics India Private Limited


SB 168, 3rd Cross, Peenya 1st Stage, Peenya Industrial Estate, Bangalore-560 058 Ph : 080-28372449/50/51 Fax : 080 28372387 Web:www.ggtronics.com

Overview

SSDAC-G36 is a fail-safe microcontroller based system with 2 out of 2 architecture suited for proving Block Section and Entry/Exit of station. Supports the following configurations with fool proof arrangement of communication path and addressing scheme.

2 DP-SS : in Straight Line (2D) 3 DP-SS : in Point Zone / Set Points (3D) 3 DP-2S : for two consecutive sections in Straight Line AS : auto signaling

Third party Verification and Validation of software completed for all configurations complying to CENELEC En50128 with SIL-4 level

22 February 2013

An Insight into SSDAC-G36

Application of SSDAC-G36

2DP version is intended for providing clear/occupied status of a single section block or entry/exit of a station. 3DP-1S version used for proving point zone/set points working

3DP-2S version employed for proving two consecutive sections in a straight line treating each independent of the other

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An Insight into SSDAC-G36

Functional Aspects

Detection and counting of wheels / axles Detection of direction of axle movement Declaring a block section as occupied on the very first count of an axle Transmission/Reception of counts, system status and many vital information to other SSDAC unit via FSK communication employing quad cable Carrying out count comparison between local and remote units Declaring the track section clear after both the local and remote counts match after clearance of the last vehicle Displaying axle counts, unit status and error messages locally in each

unit and also remotely in the Reset box connected to the unit

Logging vital information in event logger, for downloading on PC with GUI package through RS232C

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An Insight into SSDAC-G36

Functional Aspects (Contd)

Shunting operation taken care of

Train Shunting

No restrictions Single sensor sensed once - allowed Single sensor sensed twice -Error mode Dual sensor - allowed up to 3 times

Wheel Shunting

Dual Sensor - 4 times - Error mode

Communication scheme

Fail-safe feature incorporated to avoid wrong addressing Communication takes place only in fixed pairs Com1Com2 : Normal Com1Com1 : Error mode Com2Com2 : Error mode

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An Insight into SSDAC-G36

Functional Aspects (Contd)

Data Logger report retrieval (Through PC using GUI based S/W)

Local RS232 (Serial port)

Portable Data Logger (Optional)

For downloads all the events from SSDAC event logger card

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An Insight into SSDAC-G36

Main Requirements of Specification - Complied


To meet CENELEC SIL-4 Safety level Employ phase reversal technique Use of 2 out of 2 voting Data logging for 14000 events To work with 90-R, 52 Kg, 60 Kg rails Use of industrial grade components Stable operation in RE areas.

To work between 10 C to +70 C


MTBF more than 70000 hours ( As per QM115 method ) To work between train speeds of 5Kmph to 250Kmph Not to need trolley suppression circuit
An Insight into SSDAC-G36 7

22 February 2013

Salient Features

Common hardware/software for all configurations Actuates Vital and Preparatory Relays

Preparatory Reset after line verification possible


Cooperative Reset from the station master cabin Reliable inter-communication of data between the units at distances up to 25 km or -30dB loss through quad cables at 1200bps using V.23 protocol Works with 24V DC power supply

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An Insight into SSDAC-G36

Salient Features (Contd)

Wide input voltage operation from 16.8 VDC to 32.0 VDC

Wrong operations totally avoided with unique addressing of units up to 255 combinations
Upgradation to higher configuration possible Integrated with lightening surge protectors Water logging on track does not affect the functioning of the system

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An Insight into SSDAC-G36

Installation Details Cable requirement


STATION A STATION B

1/2 quad cable (optional) station master communica tion

6 core cable 1.5 Sq mm Reset and Repeat Relay Signal

2 core cable 25 Sq mm power

2 core cable 25 Sq mm power

6 core cable 1.5 Sq mm Reset and Repeat Relay Signal

1/2 quad cable (optional) station master communica tion

MODEM COMMUNICATION 1/2 quad cable START FED APPROACH DETECTORS UP DIRECTION END FED

21KHZ
TX1 RX1

25KHZ
TX2 RX2

MAXIMUM 25 KM's

21KHZ
TX1 RX1

25KHZ
TX2 RX2

APPROACH DETECTORS DOWN DIRECTION

21KHZ

25KHZ

21KHZ

25KHZ

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An Insight into SSDAC-G36

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Installation Details Typical Installation- 2DP


Railway Track

21 KHz 21 KHz
RX TX Axle De te ctors

25KHz
RX TX Axle De te ctors

25 KHz

Filter Unit

Display Unit Re lay Box Vital Re lay B Pre p Re lay B PD1 PD2

Display Unit

SPARE

SPARE

SPARE

RD1

RD2

C PU 1

SSDAC SF
To SSDAC SF Unit RS 232/ FSK Communication

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COM2

FSK Communication

PD1 PD2 SM C PU / Eve nt Logge r

Re lay Box Vital Re lay A Pre p Re lay A

DC-DC Converter

DC-DC Converter

C PU 2

SM C PU / Eve nt Logge r

Reset Box Power supply

SPARE

COM1

C PU 1

C PU 2

24VDC

24VDC

SSDAC EF
Filter Unit

To SSDAC RS 232/ FSK Communication EF Unit

Reset Box Power supply

Station A

21 KHz RX 21 KHz TX

25 KHz RX 25 KHz TX

Station B

An Insight into SSDAC-G36

11

Wheel Detection Principles


Phase detection employed Signals fed at 21Khz and 25Khz to Tx coils at 60V Phase of signal output of Rx compared with Tx AT PD Module/Card :

Under No wheel Tx and Rx signals will be 180 OUT-OF-PHASE >10V Under wheel condition Tx and Rx will be IN-PHASE <100mV

These are fed to CPU at 5V and 0V Wheels above 500mm diameter only are detected For a train at 250Kmph, pulse width is about 2.2ms Frequency of Scanning by processor for PD signal is 300s 7 times for every wheel

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An Insight into SSDAC-G36

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Wheel Detection - Train Wheel - Count

PD1

PD2

Overlap Signal

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An Insight into SSDAC-G36

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Wheel Detection - Trolley Wheel - No Count

PD1
PD2

Non-Overlap Signal

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Wheel Detection - Dip Lorry - No Count

PD1

PD2

No Detection

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Schematic - 2DP Version


Start Fed VR PR RD2 VR PR End Fed RD1 Legend : RD1, RD2 Relay Drive Card Com1, Com2 Communication Card SF Start Fed EF End Fed VR Vital Relay PR Preparatory Relay

DAC-1
Com2

DAC-2
Com1

Station A Block Section

Station B

DP-SF

Station Section

DP-EF

DP-SF

DP-EF

Station

Operation on straight lines - station or block section


Communication using 1 pair / half Quad cable or OFC voice channel Preparatory Reset with piloting PR and VR contacts at detection points
An Insight into SSDAC-G36 16

22 February 2013

System Configuration - 2DP Version


Start Fed VR PR RD2 VR PR End Fed RD1 Legend : RD1, RD2 Relay Drive Card Com1, Com2 Communication Card SF Start Fed EF End Fed VR Vital Relay PR Preparatory Relay

DAC-1
Com2

DAC-2
Com1

DAC-1
Relay Drv-2 DC-DC Converter(+24V) Phase Detector Card-1 Phase Detector Card-2 Phase Detector Card-1 Phase Detector Card-2 Com-2

DAC-2
Relay Drv-1 SM-CPU Event Logger Com-1 CPU-1 CPU-2 DC-DC Converter(+24V)

2DP Card Configuration in SSDAC G36 22 February 2013 An Insight into SSDAC-G36 17

SM-CPU Event Logger

CPU-1

CPU-2

Schematic - 3DP-1S Version


Unit A VR RD2 VR Unit B RD2 VR Unit C RD2 Legend : RD1, RD2 Relay Drive Card Com1, Com2 Communication Card VR Vital Relay

DAC-1
Com1 Com2

DAC-2
Com1 Com2

DAC-3
Com1 Com2

DP-B DP-A

DP-C

Operation on point Zones / Set points


Communication using quad cable or OFC voice channel Detection at any point and clearing at any point Preparatory Reset with LV VR contacts at detection points
An Insight into SSDAC-G36 18

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VR

Phase Detector Card-1 Phase Detector Card-2

RD2

Unit A

DAC-1

CPU-1 Com-2

Com1 Com2

DAC-1

CPU-2 Relay Drv-2 Com-1 SM-CPU Event Logger

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VR
DC-DC Converter(+24V)

RD2

Unit B

DAC-2

Phase Detector Card-1 Phase Detector Card-2 CPU-1 Com-2 CPU-2 Com-1

Com1 Com2

DAC-2

Relay Drv-2

VR

System Configuration - 3DP-1S

SM-CPU Event Logger


DC-DC Converter(+24V)

RD2

Unit C

3DP Card Configuration in SSDAC G36


Phase Detector Card-1 Phase Detector Card-2 CPU-1 CPU-2 Com-1 SM-CPU Event Logger DC-DC Converter(+24V) Com-2 Relay Drv-2

An Insight into SSDAC-G36 19

DAC-3

Com1 Com2

Legend : RD1, RD2 Relay Drive Card Com1, Com2 Communication Card VR Vital Relay

DAC-3

Schematic - 3DP-2S Version


Station-A
Reset-SF Section-A Reset-CF Section-B

Station-B
Reset-CF Section-A Reset-EF Section-B

SF SFVR-A PR A RD2

CF CFVR-A PR A CFVR-B PR B RD2 RD1 EFVR-B PR B

EF RD1

DAC-SF
Com2

DAC-CF
Com1 Com2

DAC-EF
Com1

Station A

Block Section Section A Section B

Station B

DP-SF

DP-CF

DP-EF

Legend : SF CFVR - A Com1, Com2 PR

: : : :

Start Fed Vital Relay for Sec A at Centre Fed Communication Card Preparatory Relay

CF CFVR - B EFVR - A SFVR - A

: : : :

Centre Fed EF Vital Relay for Sec B at Centre Fed Vital Relay at Sec B for End Fed Vital Relay at Sec A for Start Fed

: End Fed

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An Insight into SSDAC-G36

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Schematic 3DP-2S (Contd)


Operations on two consecutive sections on a straight line. Section A and B are independent and can be reset individually Communication using single pair / half quad cable or OFC voice channel. Co operative Preparatory reset with piloting

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SFVR-A PR A

Phase Detector Card-1 Phase Detector Card-2

Reset-SF Section-A

CPU-1 Com-2

RD2

CPU-2 Relay Drv-2

SF

DAC-SF
Station-A

Com2

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Reset-CF Section-B
SM-CPU Event Logger DC-DC Converter(+24V)

CFVR-A PR A CFVR-B PR B

Phase Detector Card-1 Phase Detector Card-2 CPU-1 Com-2 Relay Drv-2 CPU-2 Com-1 SM-CPU Event Logger Relay Drv-1

RD2

CF

DAC-CF

RD1

System Configuration - 3DP-2S

Com1 Com2

3DP-2S Card Configuration in SSDAC G36


DC-DC Converter(+24V)

An Insight into SSDAC-G36


Phase Detector Card-1 Phase Detector Card-2 CPU-1 CPU-2 Com-1 SM-CPU Event Logger Relay Drv-1 DC-DC Converter(+24V)

EFVR-B PR B EF RD1 Com1

Reset-CF Section-A

Station-B

DAC-EF

Reset-EF Section-B

22

AS or Auto Signalling

Section A

Section B

Section C

Section n+1

Block 1

Block 2

Block n+1

Operation on continuous sections in suburban areas or on a long track Up to 128 SSDACs can be daisy chained in series Communication using single pair / half quad cable or OFC voice channel Option of Preparatory Reset with or without piloting

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An Insight into SSDAC-G36

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Hardware Modules / Cards

CPU Card (CPU1 & CPU2)


Failsafe 2 out of 2 architecture for controlling and monitoring the SSDAC for reliable operation Houses the system software that schedules the overall operation as per configuration A vital card that detects the movement of train axles/wheels that is more than 550mm diameter Rejects trolley, dolly, spoke wheels and push trolley wheels Counts the total number of train axles and updates the system Communication between two SSDAC systems is through FSK communication at 1200bps V.23 standard along with CRC check Vital data like axle counts and system status are transmitted/received between the SSDAC system units Axles sensed by Detector Coils are fed to PD card which in turn feeds signal to CPU. The relay drive card receives instructions from CPU for actuating Vital relay for blocking a section as soon as the first axle is detected. It is cleared after both IN and OUT counts of the section match Generates required multiple power outputs from 24VDC input

Phase Detector Card (PD1 & PD2)

Communication Card (Com1 & Com2)

Relay Drive Card (RD1 &RD2)

Power Supply Card

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Hardware Modules / Cards (Contd)

SM-CPU or Event Logger Card

Monitors the SSDAC system and logs vital events during normal and error operation with date and time stamp As many as 95 different events are recorded Optional display connected to Event Logger Card displays the communication errors happening in Real-time which aids in assessing the health of communication channel Event logged during normal operation Communication status ok Vital and Preparatory Relay pickup / drop Reset operations Event logged during error operation Communication link fail System down due to failure of any card Vital and Preparatory Relay error status +5 VDC variations Errors

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Typical SSDAC-G36 Unit

LCD Status Display module

PD Cards

Relay Drive Card

CPU Cards Communication Card

Event Logger Card 24VDC Power Supply

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An Insight into SSDAC-G36

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Typical Site Installation

SSDAC-G36 installed in Location Box

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SSDAC-G36 unit with PR and VR Relays in a box and Display Module

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An Insight into SSDAC-G36

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Internal wiring with LDU and fuse

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Axle detector coils web mounted on to a track


An Insight into SSDAC-G36 30

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Checking for Not Sensing of Trolley wheel

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An Insight into SSDAC-G36

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Reset Box with LCD Display Clear condn of track

RESET Box installed at Station

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An Insight into SSDAC-G36

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Reset Box with LCD Display Occd condn of track

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An Insight into SSDAC-G36

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Reset Philosophy

Types of Reset

Co-operative Preparatory Reset with piloting for 2D and 3D-2S configurations Direct Reset with line verification for 3D configuration

Reset Procedure

2D : System powered onReset ModePrep ModePilotingClear

Mode

3D-2S: System powered onReset ModePrep ModePilotingClear Mode 3D : System powered on Reset ModeLVClear Mode

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Installation Procedure
The installation can be taken up with the following parallel activities

Laying foundation as per Railway standards for fixing the location box

Trenching for running the required length of cable


Drilling of track for fixing TX/RX coils with the template Fixing of TX/RX coils on the track Laying of power cables, signalling cables and cables from TX/RX coils

Painting and fixing of required planks and fuse the terminal block
Digging Earth pit and getting ready the earthing arrangement Checking for the compliance of pre commissioning check list Placing the unit along with related PCB modules/cards and Display module

Connecting earth terminal of the unit chassis to the main chassis and on to the main earth through copper cables

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35

Installation Procedure (Contd)


Placing Relay box adjacent to the unit Fixing of the MS Coupler cable assemblies on to the designated mating Couplers on the rear panel of the system

Checking continuity and insulation resistance between cable pairs and also between the chassis and the cables
Connecting all the shields and the screen wires to the earth Fixing of the reset box in a convenient location in the station

Connecting the wires coming from the system to the reset box
Connecting 24V DC to power supply Connecting the power cables coming from the system to the source of power supply of 24V DC at the station, keeping the FTB connector open

22 February 2013

An Insight into SSDAC-G36

36

Maintenance
Periodicity Weekly Maintenance Check for the proper voltage at the battery source for the unit Check and record the readings of 1. Power supply module 2. PD module 3. Check the coil Voltages Replace defective parts if any Power Supply/DC-DC Converter modules must be replaced

Fortnightly

Half yearly / Yearly

Every 5 Years

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Backup Spares (Recommended)


Sl.No 1 2 3 4 5 6 7 8 9 10 11 12 13 SSDAC Spares Phase Detector modules1&2 (PD1 and PD2) CPU1 and CPU2 Modules Communication Modules Relay drive Module Event Logger/SM-CPU Module DC-DC converter Module Axle detectors 21 KHz/25KHz (TX coil) Axle detectors 21 KHz/ 25 KHz (RX coil) Hardware for mounting axle detectors MS circular connectors (6 No.) Reset box RB SSDAC unit (housing with mother board, without modules) Relay Box Quantity 2 2 2 1 1 1 2 2 1 1 1 1 1

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Recommended Tools
Sl.No 1 2 3 4 5 6 7 8 9 10 Tools PC/Laptop for downloading event logger data for analysis and report generation Pure sine wave Digital Multimeter (Fluke make 187 or Rishab make 28S or similar Train simulator Extender module Dummy wheel Ring spanner 17-19,24-26 Open end spanner 17-19, 24-26 Socket spanner with handle Torque wrench Screw Driver No. 902 Quantity 1 1 1 1 1 1 1 1 1 1

11
12

Screw Driver No. 935


Marking jig for drilling

1
1

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An Insight into SSDAC-G36

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Trouble shooting

For ease of maintenance in the field messages are provided in the Display Module both during healthy and Error conditions About 61 possible conditions have been identified which drives the system into Error mode. The errors are displayed in plain English on the Display Module Further slides indicate the messages, their analysis and the corrective action to be taken

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Trouble Shooting
Error Code on display of CPU Errors Analysis Error occurred due to missing of the Phase detector 1 module (PD1- 21KHz) during run time and boot time diagnosis. Error occurred due to missing of the Phase detector 2 module (PD2- 25KHz) during run time and boot time diagnosis. Error occurred due to missing of the SM-CPU module during run time and boot time diagnosis. Error occurred due to missing of the Communication A module during run time and boot time diagnosis. Error occurred due to missing of the Communication B module during run time and boot time diagnosis Error occurred due to missing of the Relay Drive A module during run time and boot time diagnosis Error occurred due to missing of the Relay Drive B module during run time and boot time diagnosis Corrective measure Place the PD1 module in the slot and reset the system Place the PD1 module in the slot and reset the system Place the SM-CPU module in the slot and reset the system Place the Communication A module in the slot and reset the system Place the Communication B module in the slot and reset the system

PD1_BOARD_MISSING

PD2_BOARD_MISSING

SM_CPU_MISSING

MODEM_MODULE_A_MISSING

MODEM_MODULE_B_MISSING

RELAY_DRIVE_A_MISSING

Place the Relay Drive A module in the slot and reset the system
Place the Relay Drive B module in the slot and reset the system

RELAY_DRIVE_B_MISSING

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Trouble Shooting Contd


8 PEER_CPU_MISSING Error occurred due to missing of the any one of the CPU module during run time and boot time diagnosis When EF CPU1 could not transmit to remote unit (CF or SF) CPU1 When EF CPU1 could not transmit to remote unit (SF or CF) CPU2 When SF CPU1 could not transmit to remote unit (CF or EF) CPU1 When SF CPU1 could not transmit to remote unit (CF or EF) CPU2 Place the CPU module missing in the slot and reset the system Check the communication links (MS Coupler) and Reset the system Check the communication links (MS Coupler) and Reset the system Check the communication links (MS Coupler) and Reset the system Check the communication links (MS Coupler) and Reset the system Check the communication links (MS Coupler) and Reset the system Check the communication links (MS Coupler) and Reset the system Check the communication links (MS Coupler) and Reset the system

COMM_LU1_TO_US1_FAILURE

10

COMM_LU1_TO_US2_FAILURE

11

COMM_LU1_TO_DS1_FAILURE

12

COMM_LU1_TO_DS2_FAILURE

13

COMM_US1_TO_LU1_FAILURE

When EF CPU1 could not receive any response from the remote unit (SF or CF) CPU1
When EF CPU2 could not receive any response from the remote unit (SF or CF) CPU1 When SF CPU1 could not receive any response from the remote unit (CF or EF) CPU1

14

COMM_US2_TO_LU1_FAILURE

15

COMM_DS1_TO_LU1_FAILURE

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Trouble Shooting Contd


16 COMM_DS2_TO_LU1_FAILURE

When SF CPU2 could not receive any response from the remote unit (CF or EF) CPU1
When EF CPU2 could not transmit to remote unit (SF or CF) CPU1 When EF CPU2 could not transmit to remote unit (SF or CF) CPU2 When SF CPU2 could not transmit to remote unit (CF or EF) CPU1 When SF CPU2 could not transmit to remote unit (CF or EF) CPU2 When EF CPU1 could not receive any response from the remote unit (SF or CF) CPU2 When EF CPU2 could not receive any response from the remote unit (SF or CF) CPU2 When SF CPU1 could not receive any response from the remote unit (CF or EF) CPU2

Check the communication links (MS Coupler) and Reset the system
Check the communication links (MS Coupler) and Reset the system Check the communication links (MS Coupler) and Reset the system Check the communication links (MS Coupler) and Reset the system Check the communication links (MS Coupler) and Reset the system Check the communication links (MS Coupler) and Reset the system Check the communication links (MS Coupler) and Reset the system Check the communication links (MS Coupler) and Reset the system

17

COMM_LU2_TO_US1_FAILURE

18

COMM_LU2_TO_US2_FAILURE

19

COMM_LU2_TO_DS1_FAILURE

20

COMM_LU2_TO_DS2_FAILURE

21

COMM_US1_TO_LU2_FAILURE

22

COMM_US2_TO_LU2_FAILURE

23

COMM_DS1_TO_LU2_FAILURE

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Trouble Shooting Contd


24 COMM_DS2_TO_LU2_FAILURE When SF CPU2 does not receive any response from the remote unit (CF or EF) CPU2 Carrier signal is being blocked by modem Error occurred due to missing or error in CPU/ SM-CPU module during run time and boot time diagnosis Error at Down stream unit Error at Up stream unit Check the communication links (MS Coupler) and Reset the system Replace the faulty module Check for the error or presence of SMCPU/CPU module in the system, rectify the error and reset the system Check the error at remote unit, rectify the error and reset the system Check the error at remote unit, rectify the error and reset the system

25

MODEM_ERROR_NO_CARRIER

26

PEER_CPU_LINK_FAILURE

27 28

FAILURE_AT_DS FAILURE_AT_US

33

PD1_SUP_LOW

PD1 module supervisory is low for 3 seconds and TX and RX coils is not connected properly
PD2 module supervisory is low for 3 seconds and TX and RX coils not connected properly Error occurs when any one sensor is influenced two or more times.

Check the PD1 module, coils and reset the system


Check the PD2 module, coils and reset the system Reset the system Reset the system Reset the system

34

PD2_SUP_LOW

35 36 37

PD1_PULSING PD2_PULSING PD_STATE_MISSING

Error occurs when any one sensor is influenced two or more times.
Error occurs when double sensor is influence in the sequence

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Trouble Shooting Contd


38 39 PD_SUP_PULSATING PD_STATE_FAIL If supervisory signals pulsates more than 4 times Error occurs when any state sequence is missing Error occurs when both the PD modules doesnt sense the wheel for more than 3 times No/Improper feedback from Preparatory A relay No/Improper feedback from Preparatory B relay No/Improper feedback from Vital Relay A relay No/Improper feedback from Vital Relay B relay Without IN COUNT, OUT COUNT registered Power failure at Down stream CPU1 Power failure at Down stream CPU2 Reset the system Reset the system

40

PD_NOT_SENSING

Reset the system Check the connections of Preparatory relay A (PRA) and reset the system Check the connections of Preparatory relay B (PRB) and reset the system Check the connections of Vital relay A (VRA) and reset the system Check the connections of Vital relay B (VRB) and reset the system Reset the system Reset the system Reset the system

41

PREPARATORY_RELAY_A_FAILURE

42

PREPARATORY_RELAY_B_FAILURE

43 44 45 49 50

VITAL_RELAY_A_FAILURE VITAL_RELAY_B_FAILURE DIRECT_OUT_COUNT TRANSIENT_POWER_FAILURE_DS1 TRANSIENT_POWER_FAILURE_DS2

51
52

TRANSIENT_POWER_FAILURE_US1
TRANSIENT_POWER_FAILURE_US2

Power failure at Up stream CPU1


Power failure at Up stream CPU2

Reset the system


Reset the system

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Trouble Shooting Contd


Change the address settings by using LK10 to LK17 links and reset the system Re-program the processor and code memory checksum Change the address and configuration settings as per the requirement and reset the system

57

INVALID_NETWORK_ADDRESS

When CPU address range wrong

58

INCORRECT_CODE_CRC

This is a Boot Up error. When CRC of the code mismatches with the stored CRC When unit type and address of CPU is wrong

59

INVALID_CONFIGURATION

60

INVALID_COUNTS

Train with 10,000 wheels This is an Boot up error when RAM (In- built memory of Microcontroller) is failed

Reset the system

61

RAM_TEST_FAILED

Replace the Micro Controller

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Dos and Don'ts


Sl.No 1 2 3 4 5 6 7 8 9 10 DOs The interconnection drawings are to be followed for connecting the Transmitter and Receiver Coils. Tx1 is 21 KHz, Tx2 is 25 KHz & Rx1 and RX2 coils are 21 KHz & 25 KHz, respectively Ensure that Receiver and Transmitter coil cables are laid in different pipes. Ensure that both the TX coils & RX coils are having proper alignment on Rail. Ensure that packing of sleepers with ballast on both sides of Axle detector is proper Check that metal sheaths of the outdoor cable are connected to earth at both ends The recommended cables for wiring of the system at site should be used The steady battery voltage 24 V should be maintained. The cable connections should not be loose The M.S Coupler connectors of SSDAC are checked and maintained firmly. Preparatory Reset should be done only after ensuring that there is no train It is recommended that heat resisting paint to be used on the apparatus case so that the temperature inside apparatus case is maintained lower in comparison to other normal paints

11

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Dos and Don'ts Contd


Sl.No 1 DONTs Dont cut or join the Transmitter/Receiver cables supplied along with the coil. It would result in change of levels of signals. Dont remove the modules from SSDAC Units under POWER ON condition of system. Remove module if necessary after switching OFF the power to the Unit. Local Address of the CPU-1 and CPU 2 and configuration settings of the system should not be changed at the field. The hardware of Communication module and Relay Drive module are similar for all systems. However their positions of mounting is different in different unit types. These modules have to be equipped correctly after verifying the drawings as mentioned in the installation manual (DRG-1 to DRG-4) which indicates their positions Caution Board has to be placed near the SSDAC Axle detectors to avoid damage to the Coils from packing machines

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IV&V of Software Highlights

V&V as per CENELAC En50128 by RelQ Software has been completed successfully as below .

Review of Documents as per CENELAC En50128 Review of Source Code as per Coding Standards

White Box Testing for DE, 2D, 3D, 3D-2S, AS


HSI Testing for 2D, 3D, 3D-2S, AS Regression Testing for 2D, 3D, 3D-2S, AS Project Closure Reports

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Speed-Test using Real-time Wheel Simulator

Wheel dia 918mm RPM meter

The SSDAC G-36 speed-test setup along with Tx & Rx DPs mounted for axle detection at varying speeds from 0 to 250kmph is shown in the figure

The wheel simulator simulates actual train wheel (918mm dia) at varying speeds from 0 to 250Kmph
The speed of wheel simulator was varied from 0 to 250Kmph and axle counts of RPM meter and counts on LCD panel of SSDAC were noted The RPM counts and wheel counts on LCD panel of SSDAC matched upto max of 9999 counts and at speeds of 5, 50, 150, 200, 225, 250 kmph

Odometer

Tx Rx Coils

ALL SSDAC systems are tested with the Real-time Wheel Simulator and supplied

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Conclusion

SSDAC-G36 is a rugged system, designed to meet the stringent Railway environment. It can be easily integrated into the family of signaling systems for effortless management of Block and Section proving at stations.

22 February 2013

An Insight into SSDAC-G36

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Thank You

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